EP3862110A1 - Matériaux magnétique composites et leur procédé de fabrication - Google Patents

Matériaux magnétique composites et leur procédé de fabrication Download PDF

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Publication number
EP3862110A1
EP3862110A1 EP20156243.6A EP20156243A EP3862110A1 EP 3862110 A1 EP3862110 A1 EP 3862110A1 EP 20156243 A EP20156243 A EP 20156243A EP 3862110 A1 EP3862110 A1 EP 3862110A1
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magnetic
phase
metallic phase
transition metal
metallic
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German (de)
English (en)
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Mr. Alessandro FAIS
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Epos Technologies Sa
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EPOS Srl
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/05—Metallic powder characterised by the size or surface area of the particles
    • B22F1/052—Metallic powder characterised by the size or surface area of the particles characterised by a mixture of particles of different sizes or by the particle size distribution
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0408—Light metal alloys
    • C22C1/0416—Aluminium-based alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0425—Copper-based alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0433—Nickel- or cobalt-based alloys
    • C—CHEMISTRY; METALLURGY
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    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0466—Alloys based on noble metals
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    • C22C—ALLOYS
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    • C22C19/005—Alloys based on nickel or cobalt with Manganese as the next major constituent
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    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
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    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
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    • C—CHEMISTRY; METALLURGY
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    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
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    • C22C21/00—Alloys based on aluminium
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C—CHEMISTRY; METALLURGY
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    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/10—Alloys based on aluminium with zinc as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/12—Alloys based on aluminium with copper as the next major constituent
    • C22C21/16—Alloys based on aluminium with copper as the next major constituent with magnesium
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    • C22C—ALLOYS
    • C22C27/00—Alloys based on rhenium or a refractory metal not mentioned in groups C22C14/00 or C22C16/00
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    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy
    • C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
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    • C22C5/02—Alloys based on gold
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    • C22C5/00—Alloys based on noble metals
    • C22C5/06—Alloys based on silver
    • C22C5/08—Alloys based on silver with copper as the next major constituent
    • C—CHEMISTRY; METALLURGY
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    • C22C—ALLOYS
    • C22C9/00—Alloys based on copper
    • C22C9/04—Alloys based on copper with zinc as the next major constituent
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
    • H01F1/04—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys
    • H01F1/047—Alloys characterised by their composition
    • H01F1/053—Alloys characterised by their composition containing rare earth metals
    • H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
    • H01F1/0555—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 pressed, sintered or bonded together
    • H01F1/0557—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 pressed, sintered or bonded together sintered
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
    • H01F1/04—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys
    • H01F1/047—Alloys characterised by their composition
    • H01F1/053—Alloys characterised by their composition containing rare earth metals
    • H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
    • H01F1/057—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B
    • H01F1/0571—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes
    • H01F1/0575—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together
    • H01F1/0577—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together sintered
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
    • H01F1/04—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys
    • H01F1/047—Alloys characterised by their composition
    • H01F1/053—Alloys characterised by their composition containing rare earth metals
    • H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
    • H01F1/059—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and Va elements, e.g. Sm2Fe17N2
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
    • H01F41/0273—Imparting anisotropy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • B22F2003/1051—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding by electric discharge
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2202/00—Treatment under specific physical conditions
    • B22F2202/05—Use of magnetic field
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C2202/00—Physical properties
    • C22C2202/02—Magnetic

Definitions

  • the present invention relates to magnetic materials.
  • the invention has been developed with particular reference to sintered magnetic materials.
  • Magnetic materials available in the art cover an extremely wide range of compounds and applications, ranging from the most basic iron oxide Fe 3 O 4 up to the most modern Nd 2 Fe 14 B rare earth intermetallic compounds, developed only in 1982, with the highest magnetic properties.
  • intermetallic hard magnetic materials known in the art belong to the following families: Nd 2 Fe 14 B, Sm 2 Fe 17 N 2 , Sm 2 Co 5 , Sm 2 Co 17 and Al-Ni-Co magnets, based on the composition 8-12% Al, 15-26% Ni, 5-24% Co, up to 6% Cu, up to 1% Ti and the balance Fe.
  • Nd 2 Fe 14 B, Sm 2 Fe 17 N 2 , Sm 2 Co 5 and Sm 2 Co 17 magnets is the lack of acceptable mechanical properties due to the intermetallic nature of the chemical bonds in the crystal lattice, which prevents conventional machining with cutting tools made of steel, hard metals and cermets.
  • Bonding is generally resorted to for manufacturing magnets, called bonded magnets, with much lower magnetic properties than sintered magnets, but with tight mechanical tolerances without the need for successive machining operations.
  • Bonded magnets can be manufactured with any hard magnetic phase but, due to the lower resulting magnetic properties, they are mainly manufactured from Nd 2 Fe 14 B type flakes.
  • Hot pressing is generally resorted to for manufacturing isotropic hot pressed magnets (generally referred to as MQ2-type magnets from the company Magnequench, that first used this method).
  • Hot pressing and forging can induce anisotropy through mechanical deformation and it produces anisotropic Nd-Fe-B magnets (called MQ3 magnets).
  • MQ3 magnets anisotropic Nd-Fe-B magnets
  • other elements have been added in materials of the prior art as disclosed, for example, in KR 100446453 B1 : Al or Zn from 0.2 up to 2% in weight have been added in order, through chemical alloying, to further enhance the anisotropy of the grains, thereby obtaining a high residual magnetic field.
  • Al-Ni-Co magnets Due to their relative instability all intermetallic magnets tend to corrode quite easily and require coatings such as, for example, epoxy resins or nickel plating. Al-Ni-Co magnets, on the other hand, are better suited for machining, but have lower magnetic properties, which only allow them to be used as sensors.
  • Sm-Co magnets are interesting for high temperature applications due to the high Curie temperature thereof, while Sm-Fe-N based magnets are a known system, which is under industrial and scientific exploration for its relatively high Curie temperature of 470°C and low cost elements, but still under development.
  • a way to improve the mechanical properties of hard magnetic materials is the addition of a second non-magnetic, but strong metallic phase as disclosed in WO 2012/63407 A1 .
  • lightweight magnesium powders are mixed with ferrite (iron oxide) powders to form a mechanically robust magnet which can also be anisotropic by processing the same in a magnetic field. This was possible because of the high thermal stability of the iron oxide and the low melting point of the metal used.
  • the material remains non-machinable with conventional carbide or steel tools and the magnetic properties are essentially low (Hci max 16 kA/m) and poor, since the iron oxide has been diluted with a second, non-magnetic, phase.
  • the object of the present invention is to solve the technical problems mentioned in the foregoing. More specifically, the object of the invention is to provide a magnetic material that features, at the same time, high magnetic properties and high mechanical properties and machining capabilities.
  • Various embodiments of the invention consist of a magnetic material comprising at least one metallic phase and at least one magnetic phase, with the metallic phase(s) providing good machine processing capabilities (i.e. the material can be processed by way of machining operations, such as turning, milling, etc.), and the magnetic phase(s) achieving "hard” magnetic properties, i.e. the capability of retaining magnetic field and operating as permanent magnets.
  • each metallic phase of the magnetic material comprises one of a transition metal, a post-transition metal, and an alkali earth metal.
  • a magnetic material according to the invention may feature, for instance, a first metallic phase comprising a transition metal, and a second metallic phase comprising a post-transition metal.
  • Each group of metals concerned is intended to encompass both the metal per se, and alloys thereof, so that the invention contemplates metallic phase(s) comprising at least one of a transition metal or alloys thereof, a post-transition metal or alloys thereof, and an alkali earth metal or alloys thereof.
  • Each magnetic phase comprises one of the following:
  • a magnetic material according to the invention may feature, for instance, a first metallic phase comprising a transition metal, and a second metallic phase comprising a post-transition metal, as well as a first magnetic phase comprising a RE 2 TM 14 B alloy and a Sm 2 Fe 17 N 3 alloy, or else a single metallic phase and a single magnetic phase.
  • the total amount of the metallic phase(s) corresponds is comprised between 25% to 95% in volume of the magnetic material overall.
  • the two metallic phases together amount of 25%-95% in volume of the magnetic material overall (i.e. all of the three phases, two metallic, and one magnetic).
  • the metallic phase(s) constitutes 25% to 95% in volume of the total volume of a mixture PWMX of the metallic phase(s) and the magnetic phase(s).
  • the transition metal (again, meaning the metal per se or an alloy thereof) of the metallic phase is selected from the following group: Scandium (Sc), Titanium (Ti), Vanadium (V), Chromium (Cr), Copper (Cu), Zinc (Zn), Zirconium (Zr), Niobium (Nb), Molybdenum (Mo), Palladium (Pd), Silver (Ag), Hafnium (HF), Iridium (Ir), Platinum (Pt), or Gold (Au), paramagnetic alloys of iron (Fe), Nickel (Ni) or Cobalt (Co), diamagnetic alloys of iron (Fe), Nickel (Ni) and Cobalt (Co).
  • iron alloys providing a metallic phase in a material according to the invention comprise the following (all alloys in austenitic grade only):
  • aluminium alloys providing a metallic phase in a material according to the invention comprise the following (nomenclature following the International Alloy Designation System):
  • Examples of Copper alloys providing a metallic phase in a material according to the invention comprise the following:
  • Examples of Gold alloys providing a metallic phase in a material according to the invention comprise the following:
  • Silver alloys providing a metallic phase in a material according to the invention comprise the following:
  • Titanium alloys providing a metallic phase in a material according to the invention comprise the following:
  • Nickel alloys providing a metallic phase in a material according to the invention comprise the following Nickel alloy (non magnetic):
  • the post-transition metal (again, meaning the metal per se or an alloy thereof) of the metallic phase is selected from the following group: Aluminum (Al), Tin (Sn).
  • the alkali earth metal (again, meaning the metal per se or an alloy thereof) of the metallic phase is selected from the following group: Beryllium (Be), Magnesium (Mg).
  • the rare earth element RE comprises Neodimium (Nd), and the transition metal TM comprises iron (Fe).
  • the rare earth element RE consists of Neodimium (Nd)
  • the transition metal TM consists of iron (Fe).
  • the alloy may comprise Sm 2 Fe 17 N 2 , Sm 2 Fe 17 N 3 , or Sm 2 Fe 17 C 1.1 N.
  • the rare earth element RE' may comprise (or consist of) samarium (Sm) or Gadolinium (Gd), and the transition metal TM' may comprise or consist of Iron (Fe) or Cobalt (Co). Examples may consist of Sm 2 Co 17 and Sm 2 Co 5 .
  • the magnetic material according to the invention is manufactured by means of a method which envisages the application of pressure and voltage through a mixture PWMX of at least one magnetic phase in powdered form and at least one the metallic phase in powdered form, the mixture being placed in a forming die 1. More in detail, the method comprises at least the following steps:
  • good magnetic materials are obtained when each metallic phase and each magnetic phase have a particle size in the range 0.1 ⁇ m to 500 ⁇ m. Exceptionally good magnetic materials are obtained when each metallic phase has a particle size of 0.1 to 50 ⁇ m, and at least part of each magnetic phase, preferably at least 60% in volume of each magnetic phase, has a particle size of 50 to 500 ⁇ m.
  • the magnetic materials are formed into a desired shape by means of electro sinter forging, a sintering method disclosed in European Patent no. EP 2 198 993 B1 in the name of the same Applicant.
  • This sintering method is also known, and referred to accordingly in the following, as electro-sinter-forging.
  • the forming cavity 2 of the forming die 1 is, accordingly, delimited by the inner walls of the forming die 1 and a pair of sintering electrodes 3, 4 movable into and out of the cavity along an axis X1.
  • the forming die 1 is received in a forming machine globally designated by reference M. Pressure is therefore applied to the mixture PWMX into the forming die by means of the sintering electrodes 3, 4, and so is voltage, which is applied across the sintering electrodes 3, 4 themselves.
  • the combination of pressure and voltage applied across the electrodes 3, 4 sinter the mixture PWMX into the desired shape. Exemplary shapes are depicted in figures 8A through 8I .
  • the cross section of the forming cavity 2 matched that of the sintered material CMM: circular for figure 8A , round annular for figure 8B , rounded rectangle/flattened oval for figure 8C , square for figure 8D , rectangular for figure 8E , flattened round annular for figure 8F , triangular for figure 8G , square/rectangular with circular through opening for figure 8H , and circular with square/rectangular through opening for figure 8I .
  • the void is provided through the use of inserts or, preferably through the use of fixed or mobile core rods and properly designed plungers.
  • Such a shape might be - depending on the conditions, a final shape (already formed to tolerances) or a "green" shape ready for subsequent processing.
  • manufacturing a composite magnetic material with even better magnetic properties involves the following steps, which are configured as an evolution of the last two steps of the method.
  • the powdered mixture PWMX is inserted in the forming die 1 configured for accommodating an overlap of an electrical current I in the direction of a mechanical deformation, which is parallel to the force F applied to the plunger electrodes 3, 4 and which generates - through .
  • the forming die 1 features inlet openings intended for receiving axially movable plunger electrodes 3, 4 configured for applying mechanical pressure and voltage to the mixture PWMX in the forming cavity.
  • a constant magnetic field B is applied to the powdered mixture PWMX itself in order to align the magnetic domains of the powders during the rest of the procedure.
  • the magnetic field has to be parallel to the direction of the currents, or it should be kept exclusively during the pressing stage and should be turned off or shielded during the flow of currents.
  • Figure 7 is representative of a processing step wherein the magnetic field B overlaps a current I having a direction essentially parallel to the axis X1.
  • the magnetic field lines of field B might not be exactly as straight as the axis X1, but for the purposes of sintering the mixture PWMX into a (composite) magnetic material CMM it is sufficient for the field lines to come as close as possible to a parallel condition to the current I.
  • a nominal pressure is applied through the plunger electrodes (calculated as the force applied on/by the cross section of the plungers 3, 4 perpendicular to the current flow) between 10 to 350 MPa.
  • a voltage is also applied across the plunger electrodes 3, 4 ranging between 5 and 150 V for a time interval of 0 to 500 ms in order to develop, on the tool and powder ensemble, a specific energy input (SEI) - defined as the integral in time of the product of the real part of the voltage and real part of the current, normalized by the weight of the powders concerned - between 0.5 and 2.4 kJ/g.
  • SEI specific energy input
  • relevant magnetic properties increase when the volume percentage of the magnetic phase increases (H cB , BH max , B r ), or remain within performance-wise satisfactory values (Hci) .
  • forming the mixture of the metallic phase(s) and the magnetic phase(s) in powdered form by means of the application of pressure and voltage therethrough achieves multiple benefits and technical advantages.
  • the hard magnetic phase(s) will not degrade or only degrade marginally, thereby allowing to manufacture a fully dense metal-(hard) magnetic intermetallic composite.
  • This composite thanks to the enhanced mechanical properties provided by the metallic phase, is machinable with hard tools such as tool steels, hard metals and cermets in conventional lathes and mills without the need of abrasives machining or electro-discharge machining which are sensibly costlier and less popular machining methods.
  • a second important effect of the invention is the possibility to manufacture precious metal magnets such as, but not limited to, 22 carat, 18 carat and 14 carat gold magnets.
  • precious metal magnets such as, but not limited to, 22 carat, 18 carat and 14 carat gold magnets.
  • magnetic materials according to the present invention can be formed (e.g. electro-sinter-forged) into the shape of the buckle main body thereby providing a one piece, aesthetically appealing, golden magnetic buckle.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Hard Magnetic Materials (AREA)
  • Powder Metallurgy (AREA)
EP20156243.6A 2020-02-07 2020-02-07 Matériaux magnétique composites et leur procédé de fabrication Pending EP3862110A1 (fr)

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Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4832891A (en) 1987-11-25 1989-05-23 Eastman Kodak Company Method of making an epoxy bonded rare earth-iron magnet
US6478890B2 (en) 1997-12-30 2002-11-12 Magnequench, Inc. Isotropic rare earth material of high intrinsic induction
KR100446453B1 (ko) 2001-08-30 2004-09-01 대한민국(충남대학교) 이방성 ＮｄＦｅＢ 영구자석의 제조방법
WO2012063407A1 (fr) 2010-11-09 2012-05-18 学校法人 日本大学 Matériau composite à magnétisme dur à base de magnésium et procédé pour produire celui-ci
EP2198993B1 (fr) 2008-12-19 2012-09-26 EPoS S.r.L. Procédé de frittage et dispositif
EP2606996A1 (fr) * 2011-12-23 2013-06-26 EPoS S.r.L. Procédé de frittage de matériaux composites de matrice métallique
US20160314882A1 (en) * 2015-04-20 2016-10-27 Lg Electronics Inc. ANISOTROPIC COMPLEX SINTERED MAGNET COMPRISING MnBi AND ATMOSPHERIC SINTERING PROCESS FOR PREPARING THE SAME
US20160322136A1 (en) * 2015-04-30 2016-11-03 Jozef Stefan Institute METAL-BONDED RE-Fe-B MAGNETS
EP3093857A1 (fr) * 2013-12-30 2016-11-16 Universidad De Sevilla Procédé pour la fabrication pulvimétallurgique d'aimants
CN108538530A (zh) * 2018-05-31 2018-09-14 江苏大学 一种Nd2Fe14B/Al复合材料的制备方法及应用
CN108723355A (zh) * 2018-05-31 2018-11-02 江苏大学 放电等离子烧结制备磁性Sm2Co17/Al-Ni-Co复合材料的方法和应用
US20190153565A1 (en) * 2014-12-15 2019-05-23 Lg Electronics Inc. ANISOTROPIC COMPLEX SINTERED MAGNET COMPRISING MnBi WHICH HAS IMPROVED MAGNETIC PROPERTIES AND METHOD OF PREPARING THE SAME
DE102017131291A1 (de) * 2017-12-22 2019-06-27 Universität Rostock Verfahren zur Herstellung eines gesinterten Gradientenmaterials, gesintertes Gradientenmaterial und dessen Verwendung

Patent Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4832891A (en) 1987-11-25 1989-05-23 Eastman Kodak Company Method of making an epoxy bonded rare earth-iron magnet
US6478890B2 (en) 1997-12-30 2002-11-12 Magnequench, Inc. Isotropic rare earth material of high intrinsic induction
KR100446453B1 (ko) 2001-08-30 2004-09-01 대한민국(충남대학교) 이방성 ＮｄＦｅＢ 영구자석의 제조방법
EP2198993B1 (fr) 2008-12-19 2012-09-26 EPoS S.r.L. Procédé de frittage et dispositif
WO2012063407A1 (fr) 2010-11-09 2012-05-18 学校法人 日本大学 Matériau composite à magnétisme dur à base de magnésium et procédé pour produire celui-ci
EP2606996A1 (fr) * 2011-12-23 2013-06-26 EPoS S.r.L. Procédé de frittage de matériaux composites de matrice métallique
EP3093857A1 (fr) * 2013-12-30 2016-11-16 Universidad De Sevilla Procédé pour la fabrication pulvimétallurgique d'aimants
US20190153565A1 (en) * 2014-12-15 2019-05-23 Lg Electronics Inc. ANISOTROPIC COMPLEX SINTERED MAGNET COMPRISING MnBi WHICH HAS IMPROVED MAGNETIC PROPERTIES AND METHOD OF PREPARING THE SAME
US20160314882A1 (en) * 2015-04-20 2016-10-27 Lg Electronics Inc. ANISOTROPIC COMPLEX SINTERED MAGNET COMPRISING MnBi AND ATMOSPHERIC SINTERING PROCESS FOR PREPARING THE SAME
US20160322136A1 (en) * 2015-04-30 2016-11-03 Jozef Stefan Institute METAL-BONDED RE-Fe-B MAGNETS
DE102017131291A1 (de) * 2017-12-22 2019-06-27 Universität Rostock Verfahren zur Herstellung eines gesinterten Gradientenmaterials, gesintertes Gradientenmaterial und dessen Verwendung
CN108538530A (zh) * 2018-05-31 2018-09-14 江苏大学 一种Nd2Fe14B/Al复合材料的制备方法及应用
CN108723355A (zh) * 2018-05-31 2018-11-02 江苏大学 放电等离子烧结制备磁性Sm2Co17/Al-Ni-Co复合材料的方法和应用

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